Classifications

• • H—ELECTRICITY
  • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
  • H02K—DYNAMO-ELECTRIC MACHINES
  • H02K19/00—Synchronous motors or generators
  • H02K19/02—Synchronous motors
  • H02K19/10—Synchronous motors for multi-phase current
  • H02K19/12—Synchronous motors for multi-phase current characterised by the arrangement of exciting windings, e.g. for self-excitation, compounding or pole-changing
• • H—ELECTRICITY
  • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
  • H02K—DYNAMO-ELECTRIC MACHINES
  • H02K3/00—Details of windings
  • H02K3/46—Fastening of windings on the stator or rotor structure
  • H02K3/52—Fastening salient pole windings or connections thereto
  • H02K3/521—Fastening salient pole windings or connections thereto applicable to stators only
  • H02K3/522—Fastening salient pole windings or connections thereto applicable to stators only for generally annular cores with salient poles
• • H—ELECTRICITY
  • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
  • H02K—DYNAMO-ELECTRIC MACHINES
  • H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
  • H02K15/08—Forming windings by laying conductors into or around core parts
  • H02K15/095—Forming windings by laying conductors into or around core parts by laying conductors around salient poles
• • H—ELECTRICITY
  • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
  • H02K—DYNAMO-ELECTRIC MACHINES
  • H02K2203/00—Specific aspects not provided for in the other groups of this subclass relating to the windings
  • H02K2203/09—Machines characterised by wiring elements other than wires, e.g. bus rings, for connecting the winding terminations
• • H—ELECTRICITY
  • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
  • H02K—DYNAMO-ELECTRIC MACHINES
  • H02K5/00—Casings; Enclosures; Supports
  • H02K5/04—Casings or enclosures characterised by the shape, form or construction thereof
  • H02K5/22—Auxiliary parts of casings not covered by groups H02K5/06-H02K5/20, e.g. shaped to form connection boxes or terminal boxes
  • H02K5/225—Terminal boxes or connection arrangements

Definitions

• Electric motor with an interconnection unit and method for producing an electric motor with an interconnection unit
• the invention relates to an electric motor with an interconnection unit and a method for its production.
• an electric motor has a stator, on which a multi-phase winding is arranged.
• the winding consists, for example, of several coils connected together.
• stators are known which are constructed from wound individual teeth, in which each stator tooth therefore has one
• Each individual tooth winding forms a coil, which is made of winding wire.
• the free ends of a winding wire form the two coil connections of a coil, which usually have to be interconnected at one or both axial ends of the stator in order to form the multiphase winding.
• Star connection and delta connection are known.
• the present invention is particularly suitable for synchronous motors, the stators of which are constructed from individual stator tooth segments, each stator tooth segment each having a coil, that is to say an individual tooth winding.
• These synchronous motors in particular have a three-phase winding with the phases U, V and W, with each phase preferably being assigned a coil group.
• a coil group in turn comprises several individual coils, these coils being electrical using the interconnection unit according to the invention
• a coil connection of a coil is thus connected to another coil connection of another coil by means of an interconnection element
• connection unit contacted.
• the coil groups connected in this way are preferably connected to one another in a star connection.
• a stator unit and a motor are known from DE 1 1 2013 005 061 T5, a busbar unit being arranged on an upper side of the stator.
• An electric motor with a carrier component is known from DE 10 2014 201 637 A1, in which the winding ends are connected by means of multi-part busbars.
• an electrical machine with a connection plate in which conductor elements are used to connect the windings, the conductor elements being encapsulated with plastic for insulation.
• stator has a plurality of coils, each coil having two
• stator has a plurality of stator segments and each stator segment has exactly one coil, the coils using a
• Interconnection unit in particular in a star connection, are interconnected, the interconnection unit comprising a carrier part, in particular a substantially ring-shaped carrier part, in particular a carrier part made of an insulating material, for accommodating a plurality of, in particular at least four, spaced-apart interconnection elements, in particular with the interconnection unit on one axial end of the stator,
• first connection elements are provided, each of the first
• Connection elements each have two, in particular exactly two, contacting areas spaced apart from one another and one connected to the contacting areas
• connection area in particular so that the connection area is arranged between the contacting areas, the, in particular all, contacting areas of each first interconnection element each being connected to one of the coil connections at a respective connection point, in particular electrically connected, in particular integrally connected by means of laser welding, the one of which Connection area of one of the first interconnection elements in the circumferential and radial direction overlaps an area covered by the connection area of another of the first interconnection elements in the circumferential and radial direction.
• the terms "circumferential direction”, “radial direction” and “axial direction” refer to directions relative to the axis of rotation of the rotor.
• Axial direction thus denotes the direction parallel to the axis of rotation
• radial direction denotes the directions perpendicular to the axis of rotation and radially outward from the axis of rotation or radially inward to the axis of rotation.
• the circumferential direction is to be understood as the direction which runs along the circumference of a closed curve, in particular a circle, which runs perpendicularly and in particular concentrically to the axis of rotation.
• the term is therefore not limited to circular circumferences, but can also be used for, for example, elliptical or polygonal circumferences.
• Carrier part is disc-shaped, that is, has a continuous opening in the middle and the extent in the axial direction is less than the diameter of the carrier part in the plane perpendicular to the axis of rotation.
• the exact course of the outer and inner contours is not necessarily circular like that of a ring. Other shapes are also conceivable, such as polygonal shapes. It is also possible for the shape to deviate from the ideal circular shape, for example by having recesses on the outer circumference or on the inner circumference.
• Plastic is preferably used as the insulating material for the carrier part.
• the carrier part is produced by means of a plastic injection molding process.
• other materials can also be used which have electrical insulation properties, that is to say are insulation materials.
• the carrier part takes up the interconnection elements, so it ensures the spatial separation
• interconnection elements Arrangement of the interconnection elements to each other.
• the interconnection elements are spaced from one another, so they do not touch and are therefore not in direct contact with one another.
• the interconnection elements are made of an electrically conductive material, preferably of metal or sheet metal and in particular of copper sheet.
• Connection elements are preferably made in one piece and / or preferably as stamped and bent parts.
• the production can be carried out by means of water jet cutting or laser cutting.
• Connection point is understood to mean the place at which an electrical
• Connection between a circuit element and a coil connection is present.
• connection area connects the first
• Connection element the two contact areas.
• the contacting areas in turn serve for contacting the interconnection elements with the coil connections.
• Each first interconnection element received on the carrier part is arranged in the axial direction above or below at least one other first interconnection element.
• the first interconnection elements are therefore partially stacked one above the other in the axial direction, but without touching one another.
• the area of a connecting area covered in the circumferential and radial directions is the area which is created by projecting the corresponding connecting area parallel to the axial direction onto a projection plane perpendicular to the axis of rotation. The resulting projection surfaces of the
• Connection areas of two first interconnection elements each overlap in the projection plane.
• the advantage here is that a compact design of the interconnection unit can be achieved.
• each of the first interconnection elements has a first one
• each of the first fastening regions has a first recess running through in the axial direction and the support part has a plurality of rivet pins extending in the axial direction, a first rivet pin being able to be passed through each of the first recesses, the free ends of the first rivet pins,
• rivet heads are formed into rivet heads, in particular by means of ultrasonic welding.
• hot caulking or hot stamping can also be carried out.
• the recess can be designed, for example, as a particularly cylindrical hole.
• a hole is an example of a closed recess. However, they are also open
• Recesses conceivable which do not form a closed curve in the plane perpendicular to the axis of rotation.
• a notch in the axial direction also represents one
• the recess runs continuously in the axial direction and is suitable for contributing to a positive and / or material connection with the carrier part.
• a rivet pin is to be understood as an extension in the axial direction, which is shaped in such a way that it can be passed through the recesses of the first connection elements in the axial direction.
• the rivet pin is designed as a cylindrical extension in the axial direction.
• the diameter of the rivet head in the plane perpendicular to the axis of rotation is selected to be larger than the diameter of the corresponding recess in the same plane.
• each of the first interconnection elements each has a second fastening area for positive and / or material connection to the carrier part, in particular each of the second fastening areas each having a second recess in the axial direction, with a second rivet pin through each of the second recesses can be passed through, the free ends of the second rivet pins, in particular by means of ultrasonic welding, being formed into rivet heads.
• Connection elements on the carrier part is accessible, so that moving the carrier part
• the first fastening areas of each of the first interconnection elements each have the same first radial position and / or in each case the same first axial position and / or the second fastening areas of each of the first
• Interconnection elements each have the same second radial position and / or the same second axial position, in particular wherein the first radial position and the second radial position are different, in particular wherein the first axial position and the second axial position are different.
• the advantage here is that the spatial fixation of the first interconnection elements on the carrier part is further improved. Tilting of the interconnection elements relative to the
• Carrier part is prevented.
• the carrier part has a plurality of guide areas on its outer circumference for guiding the coil connections in the axial direction, with each contact area connected to a coil connection being assigned a guide area, in particular the shape of the guide area essentially being the same as the shape of the respectively assigned contact area ,
• the step of contacting the coil connections with the interconnection unit can be carried out more reliably.
• the guidance of the coil connections ensures that the coil connections are aligned essentially parallel to the axis of rotation.
• the coil connections can advantageously be clamped on the guide areas and thus facilitate the method step of establishing a material connection between
• a second connection element which has three, in particular exactly three, contact areas, each of the three contact areas of the second connection element each having one of the
• Coil connections is connected, in particular electrically connected, in particular cohesively connected by means of laser welding.
• the advantage here is that the coils can be connected in a neutral connection.
• the second connection element serves as a neutral point element for connecting three different coil connections.
• the second connection element is dispensable for a connection in a delta connection.
• the second connection element has two, in particular exactly two, fastening areas for positive locking and / or
• Fastening area each has a continuous recess in the axial direction and a third rivet pin can be passed through each of the recesses, in particular the free ends of the third rivet pins, in particular by means of
• the advantage here is that a better and more stable spatial fixation of the second circuit element on the carrier part can be achieved, so that a movement of the
• Connection element is prevented relative to the carrier part.
• Interconnection elements are provided, each of which has a first contacting area and a second contacting area, which are in particular designed differently, the first contacting area of a third
• Connection element is each connected to one of the coil connections, in particular electrically connected, in particular cohesively connected by means of laser welding.
• the advantage here is that a simple connection of the, in particular three, phase conductors to the electric motor is made possible.
• the third connection elements are electrically connected to the first contacting area with those coils which are each to be connected to a phase.
• the second contact area is then suitable for connecting the third interconnection elements to the phase conductor, in order to establish an electrical connection between the phase conductor and the coil. The connection is made
• cable lugs of the phase conductors are fastened to the second fastening area using a screw and nut.
• each of the third interconnection elements has a first and a second fastening region for the positive and / or material connection to the carrier part, in particular each of the two
• Fastening areas each have a continuous recess in the axial direction and a fourth rivet pin can be passed through each of the recesses, in particular the free ends of the fourth rivet pins, in particular by means of
• Connection elements on the carrier part is accessible, so that moving the carrier part
• each of the third interconnection elements has a third fastening area for positive and / or material connection to the carrier part, the third fastening area adjoining the first contact area of the respective third interconnection element,
• the third fastening region having a recess which is continuous in the axial direction and through which a fifth rivet pin can be passed, in particular with the free ends of the fifth rivet pin, in particular by means of
• the advantage here is that the spatial fixation of the third interconnection elements on the carrier part is further improved.
• the contacting areas are every first
• connection element shaped such that the respective connection points each have essentially the same radial position, in particular on the outer circumference of the carrier part, and / or each have the same axial position.
• connection points are advantageously arranged on the outer circumference of the carrier part, so that there is easy accessibility.
• the areas covered by the connection areas of the first interconnection elements in the axial direction are the same.
• the advantage here is that installation space can be saved in the axial direction, so that a compact design of the interconnection unit can be achieved in the axial direction.
• the areas covered by the connection areas of the first interconnection elements in the radial direction are the same.
• connection area has each of the first
• Connection elements have a cross-section, in particular approximately rectangular, the extent of which in the axial direction is less than the extent of the latter in the radial direction.
• the advantage here is that installation space can be saved in the axial direction.
• At least one connection area of one of the first interconnection elements has two axial steps, in particular all of them
• connection areas of the first interconnection elements each have two axial steps.
• the advantage here is that a partial stacking of the first
• connection elements is simplified. Instead of discrete steps in the connection area, an inclination of the connection area running in the axial direction, in particular constant, is also possible, so that the two contacting areas have different axial positions and partial stacking on one another is made possible.
• Interconnection elements in the circumferential and radial directions covered areas two areas each covered by two other first interconnection elements in the circumferential and radial directions.
• the advantage here is that a more compact design of the interconnection unit can be achieved.
• the wording is to be understood such that three first interconnection elements are arranged axially one above the other in certain circumferential and radial areas.
• Connection elements in particular the area covered by all first connection elements in the radial direction, are the same.
• the advantage here is that installation space can be saved in the radial direction, so that a compact design of the interconnection unit can be achieved in the radial direction.
• the advantage here is that a compact design of the interconnection unit can be achieved.
• the first interconnection elements are of identical construction and / or the third interconnection elements are of identical construction.
• the interconnection unit has a type of first interconnection elements and / or a type of third
• Connection elements can be manufactured. This facilitates, in particular, the automated production of the first interconnection elements, for example if they are machined as punched and bent parts.
• At least one of the first interconnection elements is surrounded by an insulating part made of insulating material, in particular by means of an injection molding process, such that the surrounding first interconnection element and the
• surrounding insulating part are positively connected on both sides in the circumferential direction and / or are positively connected on both sides in the axial direction and / or are positively connected in the radial direction on one side, in particular wherein in the circumferential direction only every second of the first interconnection elements is surrounded in this way by a respective insulating part.
• Interconnection elements are easily accessible. Using prefabricated insulating parts, shorter distances between the first interconnection elements can be achieved while at the same time ensuring appropriate creepage distances for sufficient electrical insulation. Alternatively, the first would be overmolded
• Interconnection elements can be implemented with an insulating material. However, this procedure is more difficult to carry out and more expensive.
• the coil connections are cohesive
• the advantage here is that the contacting can be carried out so quickly by means of laser welding that there is no appreciable heating of the first interconnection elements. This allows the welds to be close to parts made of insulating material, in particular
• Plastic lie without damaging and / or deforming them through heating.
• Winding wires can always be made a safe and reliable electrical connection.
• the wire is always symmetrical to the axis of symmetry of the notch and touches the
• Contact area can be used for different wire diameters.
• first interconnection elements each have two, in particular exactly two, contacting areas and the first interconnection elements are arranged such that the area covered by one of the first interconnection elements in the circumferential and radial directions is in each case one of one
• first interconnection elements are arranged spaced from each other, iii) connecting the first interconnection elements to the carrier part, in particular positive and / or material connection, to form a
• the advantage here is that a compact design of the interconnection unit can be achieved.
• each of the first interconnection elements each has a first fastening area for positive and / or material connection to the carrier part, in particular wherein each of the first fastening areas each has a first recess that extends in the axial direction and the carrier part has a plurality of rivet pins that extend in the axial direction, in particular with a first rivet pin being passed through each of the first recesses in step iii), the free ends of the first rivet pins being subsequently formed into rivet heads, in particular by means of ultrasonic welding.
• Connection elements and the carrier part is executable.
• step ii) the first
• Interconnection elements arranged in such a way that only every second one of the first interconnection elements in the circumferential direction is surrounded by an insulating part made of an insulating material, in particular by means of an injection molding process, the surrounding first interconnection element and the surrounding insulating part being positively connected on both sides in the circumferential direction and / or positively on both sides in the axial direction are connected and / or are positively connected on one side in the radial direction.
• Interconnection elements are easily accessible. Using prefabricated insulating parts, shorter distances between the first interconnection elements can be achieved while at the same time ensuring appropriate creepage distances for sufficient electrical insulation. Alternatively, the first would be overmolded
• Interconnection elements can be implemented with an insulating material. However, this procedure is more difficult to carry out and more expensive.
• a second connection element is arranged on the carrier part, the second connection element having three, in particular exactly three, contacting areas,
• step iii) the second to form the interconnection unit
• Connection element is connected to the carrier part, in particular is positively and / or cohesively connected, wherein, in particular in step iv), each of the contacting areas of the second
• Connection element is connected to one of the coil connections
• the advantage here is that the coils can be connected in a neutral connection.
• the second connection element serves as a neutral point element for connecting three different coil connections.
• Interconnection elements each have two, in particular different, contacting areas, wherein, in particular in step iii), the third interconnection elements are connected to the carrier part to form the interconnection unit, in particular are connected in a form-fitting and / or integral manner, with one in particular in step iv) the two contacting areas of the third interconnection elements are each connected to one of the coil connections, in particular is electrically connected, in particular is integrally connected by means of laser welding.
• the advantage here is that a simple connection of the, in particular three, phase conductors to the electric motor is made possible.
• the third interconnection elements are connected with one of their contacting areas to those coils which are each to be connected to a phase. These coils are then simply connected to the phase conductors, for example using cable lugs.
• stator with coils and the interconnection unit connected to the coil connections in particular after step iv), the stator with coils and the interconnection unit connected to the coil connections
• Potting compound in particular such that the contacting areas of the third interconnection elements, which are not connected to a coil connection, remain free of potting compound.
• the advantage here is that a stable mechanical fixation of the interconnection unit on the stator can be achieved.
• FIG. 1 shows a perspective view of a first embodiment of an interconnection unit arranged on a stator of an electric motor according to the invention.
• FIG. 2A the stator and the first embodiment of the interconnection unit from FIG. 1 are shown in a side view.
• FIG. 2B shows the stator and the first embodiment of the interconnection unit from FIG. 1 in a top view.
• FIG. 3A shows a first interconnection element of the first embodiment of FIG.
• FIG. 3B shows the first connection element of FIG. 3A in a side view.
• FIG. 3C shows a projection in the axial direction onto a plane of the first connection element from FIGS. 3A and 3B that is perpendicular to the axis of rotation.
• FIG. 4 shows a second connection element of the first embodiment of the
• FIG. 5A shows a third interconnection element of the first embodiment
• FIG. 5B shows the third interconnection element from FIG. 5A in a top view.
• FIG. 6 shows the carrier part of the first embodiment of the interconnection unit from FIG. 1 with the second interconnection element from FIG. 4 arranged thereon in a perspective view.
• FIG. 7A shows the first connection element from FIG. 3A with an insulating part pushed on in a perspective view.
• FIG. 7B shows two first interconnection elements in a perspective view.
• FIG. 7C shows a projection in the axial direction onto a plane of the two first interconnection elements from FIG. 7B perpendicular to the axis of rotation.
• FIG. 8 shows the carrier part of the first embodiment of the interconnection unit from FIG. 1 with interconnection elements arranged thereon in a perspective view.
• FIG. 9A shows an insulating part of the second embodiment of the interconnection unit in a perspective view.
• FIG. 9B shows a first connection element of the second embodiment of the
• Connection unit shown in a perspective view.
• FIG. 9D shows the insulating part and the first connection element from FIG. 9C and a further first connection element in a perspective view.
• FIG. 10 shows an interconnection unit of the second embodiment in one
• Figure 1 shows a perspective view of a first embodiment of a
• Interconnection unit 1 which is arranged at an axial end of a stator 2 of an electric motor according to the invention, not shown.
• Electric motor is made up of individual stator segments 3. In the shown
• the stator 2 has twelve stator segments 3.
• the number twelve is only an example, other numbers of stator segments are also conceivable.
• stator segments 3 are preferably embodied as punch-packaged laminated cores.
• stator segments 3 are connected to one another in such a way that they form an essentially cylindrical stator 2. Inside the stator 3 is a rotor, not shown
• the rotor and stator 2 are arranged concentrically to the axis of rotation D.
• the rotor preferably has permanent magnets and the electric motor is preferably designed as a permanently excited synchronous motor.
• Each stator segment 3 has a stator tooth, around which a coil 4 is wound.
• the coil is made of insulated winding wire. The two ends of the
• Winding wire are stripped and form the two coil connections 5, 6.
• the coils 4 are only shown schematically in Figure 1. Between the coils 4 and
• Stator segments 3 are for electrical insulation, for example insulating paper 7.
• FIG. 2A shows the arrangement from FIG. 1 in a side view.
• the direction A which runs parallel to the axis of rotation D, is referred to as the axial direction.
• Figure 2B shows the
• the radial direction R is defined starting from the axis of rotation D.
• the radial direction R thus runs perpendicular to the axial direction A.
• the circumferential direction U runs along the circumference of the stator 2 and is also shown in FIG. 2B.
• the individual coils 4 are multiphase by means of the interconnection unit 1
• the twelve coils 4 are connected to one another in a star connection, a three-phase winding being formed. Four individual coils 4 are therefore assigned to each phase. Within one phase, the four coils 4 are connected in series by means of the interconnection unit 1. All three phases are connected to each other at the star point. The individual elements of the interconnection unit 1 are explained in the following figures for a better overview.
• the interconnection unit 1 comprises a plurality of interconnection elements 30, 40, 50 for interconnecting the coil connections and a carrier part 60 for accommodating the interconnection elements 30, 40, 50.
• a carrier part 60 for accommodating the interconnection elements 30, 40, 50.
• first interconnection elements 30 and a second interconnection element 40 are necessary. If n denotes the number of phases and z the number of stator segments 3 and, accordingly, the number of coils 4, first interconnection elements 30 and a second interconnection element 40 are necessary for a star connection (z-n).
• the second connection element 40 is therefore only necessary for a star connection.
• Interconnection for example delta connection, it is dispensable.
• FIG. 3A shows a first connection element 30 in a perspective view.
• the first interconnection element 30 is made of sheet metal, preferably sheet steel or copper sheet, and is preferably manufactured as a stamped and bent part.
• the first interconnection element 30 comprises a first contacting area 31 and a second contacting area 32.
• the two contacting areas 31, 32 are spaced apart from one another. Between the two contacting areas 31, 32 is a
• connection area 33 arranged.
• the connection area 33 connects the two
• the contacting areas 31, 32 are used for the electrical and mechanical connection of the first interconnection element 30 to the
• a contacting area 31, 32 is connected to a coil connection 5, 6.
• the contacting areas 31, 32 have a V-shaped notch 301 for receiving a coil connection 5, 6 in the form of a
• the first connection element 30 comprises a first fastening region 34 and a second fastening region 35
• Fastening areas 34, 35 serve to fasten the first interconnection element 30 on the carrier part 60.
• the present exemplary embodiment the
• Fastening areas 34, 35 each have a continuous recess 36, 37 in the form of a cylindrical hole.
• semi-open recesses can also be made, for example in the form of an axially extending groove.
• FIG. 3B shows the first connection element 30 from FIG. 3A in a side view.
• the first interconnection element has a first stage 37 and a second stage 38. These steps 37, 38 are preferably made by bending. Because of these steps 37, 38, the first and the second
• FIG. 3C shows a vertical projection of the first interconnection element 30 from FIG. 3A onto a plane perpendicular to the axis of rotation.
• the steps 38, 39 from FIG. 3B are therefore not recognizable.
• the hatched area B1 shows that of the connecting area 33 in
• Circumferential and radial direction covered area Circumferential and radial direction covered area.
• FIG. 4 shows a second connection element 40 in a perspective view.
• the second interconnection element 40 is made of sheet metal, preferably sheet steel or copper sheet, and is preferably manufactured as a stamped and bent part.
• the second interconnection element 40 comprises a first contacting area 41, a second contacting area 42 and a third contacting area 43.
• Contacting areas 41, 42, 43 are spaced apart from one another. There is a between the first contacting area 41 and the third contacting area 43
• Connection area 44 arranged.
• the second contacting area 42 is also arranged on the connecting area 44.
• the connecting area 44 thus connects the three contacting areas 41, 42, 43 to one another.
• the contacting areas 41, 42, 43 are used for the electrical and mechanical connection of the second interconnection element 40 to the coil connections 5, 6.
• a contacting area 41, 42, 43 is connected to a coil connection 5, 6 in each case.
• the contacting areas 41, 42, 43 have a V-shaped notch 401 for receiving a coil connection in the form of a
• the second interconnection element 40 forms with an interconnection of three Phases in star connection the star point at which the three phases are connected.
• the second comprises
• Connection element 40 a first fastening area 45 and a second
• the fastening areas 45, 46 serve to fasten the second connection element 40 on the carrier part 60.
• the fastening areas 45, 46 each have a continuous recess 47 in the form of a cylindrical hole. Alternatively, they are also semi-open recesses
• FIG. 5A shows a third connection element 50 in a perspective view.
• the third interconnection element 50 is made of sheet metal, preferably sheet steel or copper sheet, and is preferably manufactured as a stamped and bent part.
• the third interconnection element 50 comprises a first contacting area 51 and a second contacting area 52.
• the two contacting areas 51, 52 are spaced apart from one another.
• the first contact area 51 serves for the electrical and mechanical connection of the third connection element 50 to a coil connection 5, 6 and for this purpose has a V-shaped notch 501.
• the second contact area 52 is used for the electrical and mechanical connection of the third interconnection element 50 to a phase conductor.
• the third interconnection elements 50 thus form the connections of the
• Connection elements 50 and the phase conductors can be directly or indirectly via a
• Screw 80 with associated nut 81 In principle, a direct one
• interconnection elements 50 simplify the manufacturing process of the electric motor and make it easier to connect the phase conductors to the electric motor.
• the second contacting area 52 has a
• the third connection element 50 comprises a first fastening area 53, a second fastening area 54 and a third fastening area 55.
• the fastening areas 53, 54, 55 serve to fasten the third connection element 50 to the carrier part 60
• the fastening areas 53, 54, 55 have half-open recesses 56, 57 in the form of axially extending grooves. Alternatively, they are closed
• Recesses for example, in the form of cylindrical holes.
• FIG. 6 shows the carrier part 60 with a second interconnection element 40 held thereon.
• the carrier part 60 is essentially ring-shaped and is in it
• Embodiment designed as a plastic injection molded part. It is preferably made in one piece.
• the carrier part 60 is arranged concentrically to the axis of rotation D at an axial end of the stator 2, as shown in FIG. 1.
• the carrier part 60 has axial extensions 61, 62, 63, 64, 65 in the form of rivet pins.
• the extensions 61, 62, 63, 64, 65 in the form of rivet pins.
• the rivet pins 61, 62, 63, 64, 65 are preferably complementary to the corresponding ones
• Recesses 36, 37, 47, 56, 57 designed to enable a stable mechanical connection between the carrier part 60 and the connection element 30, 40, 50.
• the carrier part 60 has first rivet pins 61 and second rivet pins 62 for holding the first connection element 30.
• the carrier part 60 preferably has third rivet pins 63 for holding the second connection element 40.
• the carrier part 60 preferably has fourth rivet pins 64 and fifth rivet pins 65 for holding the third connection elements 50.
• the first, third and fourth rivet pins are advantageously arranged close to the inner circumference of the carrier part 60, while the second and fifth rivet pins are arranged close to the outer circumference of the carrier part 60.
• the latter Distributed on the outer circumference of the carrier part 60, the latter has a plurality of guide regions 66.
• Each guide area 66 has a V-shaped notch and is used to guide the coil connections 5, 6 in the axial direction when establishing the electrical connection between the coil connections 5, 6 and the contacting areas 31, 32, 41, 42, 43,
• Circumferential direction essentially the position of a corresponding one
• a guide area 66 is arranged axially below a contacting area 31, 32, 41, 42, 43, 51.
• the V-shaped notch of the guide region 66 is slightly offset in the radial direction, for example 0.5 mm, towards the inner circumferential side, so that there is good contact between
• the coil connections 5, 6 are first bent so that they point radially outwards. Subsequently, the interconnection unit 1 is placed on the stator 2 and then the coil connections 5, 6 are bent into position so that they point axially upwards and touch the corresponding contacting areas 31, 32, 41, 42, 43, 51.
• the guide areas 66 support the process of
• the starting point in the method for producing the interconnection unit 1 is the carrier part 60 made of insulating material. In the present exemplary embodiment, this is produced from plastic by means of injection molding. Thereafter, as shown in FIG. 6, the second interconnection element 40 is arranged on the carrier part 60. The continuous recesses 47 of the fastening areas 45, 46 of the second serve for mounting
• the first interconnection elements 30 are arranged on the carrier part 60 in such a way that the area covered by the connecting area 33 of one of the first interconnection elements 30 in the circumferential and radial directions (B1,
• Connection elements 30 overlap area (B1, B2) covered in the circumferential and radial directions.
• the first interconnection elements are in the circumferential direction at least partially stacked axially one above the other, so that a more compact design is possible.
• the continuous ones serve to hold the first interconnection elements 30
• Recesses 36, 37 is possible.
• the fact that one of the two recesses 36, 37 of a first interconnection element 30 is arranged radially further inwards than the other recess 37 enables stable holding. In particular, tilting of the first interconnection elements 30 is avoided.
• the first fastening regions 34 have a radial position which is different from the radial position of the second fastening regions 35.
• the first and second rivet pins 61, 62 and the first interconnection elements 30 are arranged and shaped in such a way that the placed first interconnection elements 30 do not touch one another. So they are spaced from each other. In principle, no further electrical insulation is necessary as the stator is in a final one
• Manufacturing step is usually cast with potting compound, which as
• Insulation material is used.
• Connection elements 30 also take place through prefabricated insulating parts.
• insulating parts 70 are made of plastic, for example, by means of injection molding.
• FIG. 7A shows an insulating part 70 which partially surrounds a first connection element.
• insulating part 70 is shaped such that it can be pushed onto the first interconnection element 30 in the radial direction.
• the first interconnection element 30 is partially surrounded in the circumferential direction by the insulating part 70 such that it is not possible to move the insulating part 70 and the first interconnection element 30 against one another in this direction. It is therefore a positive connection on both sides
• first interconnection element 30 is partially surrounded in the axial direction by the insulating part 70 in such a way that the insulating part 70 and the first interconnection element 30 cannot be displaced in this direction. So there is a positive connection on both sides in the axial direction.
• the first interconnection element 30 is only positively connected to the insulating part 70 on one side, so that it can be displaced relative to one another. If insulating parts 70 are used for electrical insulation, it is advantageously possible for only every second of the first interconnection elements 30 to be surrounded by an insulating part 70 in the circumferential direction, as described above.
• Figure 7B shows the first
• FIG. 7C shows a perpendicular projection of the two first interconnection elements 30A, 30B from FIG. 7BA onto a plane perpendicular to the axis of rotation.
• the insulating part 70 is not shown here.
• the hatched area B1 shows that of FIG. 3C
• Connection area 33 of a first interconnection element 30 in circumferential and
• the hatched area B2 indicates the area covered by the connecting area 33 of the other first interconnection element 30B in the circumferential and radial directions. These two areas partially overlap. In this embodiment, those of the two connection areas 33 are in
• FIG. 8 shows the carrier part 60 and the second interconnection element 40 from FIG. 6 with the nine first interconnection elements 30 arranged thereon and the insulating parts 70 arranged therebetween. Since only every second connection element 30 is surrounded by an insulating part 70, only five insulating parts 70 are in this exemplary embodiment necessary.
• a third connection element 50 is shown in FIG. 8, which is held by two fourth rivet pins 64 and a fifth rivet pin 65 of the carrier part 60.
• a square screw 80 with associated nut 81 is used to contact the third connection element 50 with the phase conductor. The head of the screw is arranged axially below the continuous recess of the second fastening area 52, so that the hexagon nut 81 is accessible from above.
• the interconnection elements 30, 40, 50 are arranged on the carrier part 60, they are connected to the carrier part 60.
• the free ends of the rivet pins 61, 62, 63, 64, 65 are formed into rivet heads in such a way that the diameter of the rivet heads in the plane perpendicular to the axis of rotation is larger than that
• Diameter of the corresponding recesses can be carried out, for example, by means of ultrasonic welding or hot caulking or hot stamping. If at
• the coil connections 5, 6 are connected to the corresponding contacting areas 31, 32,
• the stripped wire ends of the coils are inserted into the V-shaped notches 301, 401, 501 of the contacting areas 31, 32, 41, 42, 51 and a cohesive connection is established between the wire and the connection element.
• this is done by means of laser welding.
• the stator 2 together with the interconnection unit 1 arranged at an axial end of the stator is cast with casting compound for mechanical fixing. If no insulating parts 70 are used, this potting compound serves as electrical insulation between the interconnection elements 30, 40, 50.
• the third interconnection elements 50 advantageously have anchor areas 58 which are separated from the third Show fastening area axially in the direction of the stator 2.
• the anchor area 58 advantageously has an undercut 59.
• FIG. 9B shows, alternatively for a second exemplary embodiment of an interconnection unit 1, a first interconnection element 90.
• This first interconnection element 90 also has a first contacting area 91 and a second contacting area 92.
• Contacting areas 91, 92 each comprise a catch arm 93, with which a respective coil connection 5, 6 can be caught and non-positively held, in particular clamped between the catch arms.
• the coil connections 5, 6 are preferably integrally connected to the tentacles by means of contact welding.
• the catch arms 93 are opened in a V-shape, the catch arms forming the legs of the V.
• a quick and inexpensive electrical connection of the coil connections 5, 6 to the contacting areas 91, 92 is made possible by the catch arms 93 by turning the coil connections 5, 6 into the inner area spanned by the contacting area 91, 92 when the interconnection unit 1 is rotated relative to the stator 2 , in particular in the inner area spanned by the V of the V-shaped catch arm 93.
• the respective contacting area 91, 92 thus threads the respective coil connection 5, 6 up to the connection position on the inner tip of the V.
• contact welding connection is carried out.
• connection region 94 of the first interconnection element 90 of the second exemplary embodiment has two axial steps 95, 96.
• this first interconnection element 90 has only one fastening area 97.
• the attachment area has a
• FIG. 9A shows an insulating part 99 which is pushed onto the first connection element 90.
• FIG. 9C shows the first interconnection element 90 with the insulating part 99 pushed on.
• FIG. 9D shows the first interconnection element 90A with the insulating part 99 from FIG. 9C pushed on, and additionally a further first interconnection element 90B which is on the
• Insulating part 99 is arranged.
• FIG. 10 shows the interconnection unit 100 of the second exemplary embodiment.
• the interconnection unit 100 has a carrier part 101 for holding the nine first interconnection elements 90, the second interconnection element 102 and the three third interconnection elements 103.
• the second interconnection element 102 has three
• the second connection element 102 has two fastening regions 105, of which only one is visible due to the perspective illustration.
• the third interconnection element 103 has a first contacting area 106 for contacting a coil terminal 5, 6 and a second contacting area 107 for contacting a phase conductor.
• the third interconnection element 103 has only one fastening region 108.
• the positive connection between the interconnection elements 90, 102, 103 and the carrier part 101 is also achieved in the second exemplary embodiment by reshaping rivet pins of the carrier part, which can be passed through recesses in the respective fastening regions, to form rivet heads.
• the interconnection elements 90, 102, 103 are positioned on the carrier part 101 in that the carrier part 101 has a circumferential annular groove for receiving the interconnection elements 90, 102, 103.
• the carrier part 101 has recesses 109 in the groove wall on its outer circumference which can be passed through the contacting areas 91, 92, 104, 106, respectively. This also contributes to the precise positioning of the components.
• all of the first interconnection elements 30, 90 are of identical construction, that is, identical parts. They are also the third
• Connection elements 50, 103 are constructed identically, that is, identical parts. This has the advantage that the parts can be manufactured more cheaply. However, it is also possible for the first interconnection elements 30, 90 and / or the third interconnection elements 50, 103 to be designed differently.
• both the areas covered by the connecting areas 33, 94 of the first interconnection elements 30, 90 in the axial direction and the areas covered by the connecting areas 33, 94 of the first interconnection elements 30, 90 in the radial direction are the same. However, it is also possible that these areas are different.

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• Engineering & Computer Science (AREA)
• Power Engineering (AREA)
• Manufacturing & Machinery (AREA)
• Insulation, Fastening Of Motor, Generator Windings (AREA)
• Manufacture Of Motors, Generators (AREA)

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• 2019
  • 2019-07-04 WO PCT/EP2019/025215 patent/WO2020015857A1/de active Application Filing
  • 2019-07-04 DE DE102019004589.0A patent/DE102019004589A1/de active Pending
  • 2019-07-04 CN CN201980048100.2A patent/CN112425043B/zh active Active
  • 2019-07-04 EP EP19739511.4A patent/EP3824530B1/de active Active
  • 2019-07-04 US US17/261,305 patent/US11876414B2/en active Active

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